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Installation diagram for:

3 DOWNPIPE KIT #1029


1994-1998 FORD F250 / F350
7.3L POWERSTROKE DIESEL

PACKING LIST

Qty Description Part #

1 Upper Down Pipe 26137


1 Lower Down Pipe 26139
1 Heatshield HS111
1 Parts Kit PK387
1 3 Ring Clamp MC300R
1 Flange SF030
2 3-3/4 Hose Clamp MC375H
2 3/8 NC x 2-1/2 Hex Bolts
2 3/8 NC Hex Nuts
2 3/8 Flat Washers
2 3/8 Split Lock Washers
12/15/09
Removal

1) Begin by removing the two nuts that secure the factory downpipe to the front of the catalytic converter
under the truck. Application of a penetrating lubricant is recommended.

2) Using a sawsall with a 9 blade, carefully cut the bottom section of the factory downpipe off. There is
not much room to work, but try to get the cut as far up towards the turbo as you can. The goal of cutting this
pipe is to be able to remove the upper section of the pipe down through the bottom. If the pipe is not cut off
far enough up, the pipe will get bound up when attempting to remove it.

3) Now lift the hood of the vehicle and locate the V-band clamp at the rear of the turbo unit. This clamp
secures the down pipe to the turbo. Loosen the nut on the clamp enough to release the clamp and the down
pipe. Due to the V-taper of this clamp, the clamp may not release from the connection after the bolt is
loosened. It may be necessary to bang on the pipe from below or carefully pry on the clamp to get the taper
joint to release. Once it pops loose, remove and save the clamp for use with the new Flowmaster down
pipes.

4) The remaining upper portion of the downpipe should now be able to be removed out through the
bottom with some patient twisting and turning.

5) The upper section of the transmission dip stick tube should now be removed before attempting to
install the new Flowmaster pipe. This is done by removing the bolt that secures it to the right/rear side of the
engine.

Installation

1) From under the vehicle, if you look up towards the turbo there is a lip seam that runs across on the
firewall. This seam must be modified to gain enough clearance to get the new 3 diameter downpipe
between the bell housing and firewall. This can be done by one of a few methods that you have to choose
from: 1) A die grinder or cut-off wheel can be used to trim the appropriate portion of the seam. 2) A
hydraulic porta-power can be used with a properly placed spreader attachment to push the effected area of
the firewall over. 3) The method we prefer is to use a small crescent wrench placed on the seam to bend it
back. This is done a little at a time, moving along the length of the seam.

2) From the top, feed the upper pipe section #26137 down between the firewall and engine. This is a
tight fit that may really take some patient twisting, turning, pushing and whatever else, to get the pipe down
into position on the back of the turbo housing flange. Once in place, install the factory V-band clamp to hold
the pipe in place. Tighten just enough to hold in position.
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3) *Important* Prepare the lower section pipe #26139 by first sliding the provided flange onto the
pipe and then sliding on the provided ring clamp. You cant go back and put these on after the pipes
are assembled.

4) Back down under the vehicle, put the lower pipe up into position and slide it into the upper
pipe. Use the provided bolts, nuts and washers to connect the two flanges at the catalytic converter
ball flare connection. Slide the ring clamp up to the slip-joint between the upper and lower pipe and
tighten just enough to hold in place.

5) At this point, all of the parts now need to be adjusted by prying, wiggling, turning, etc. to attain
proper fit and with adequate clearance. Once this is done, go back and securely tighten up the turbo
outlet V-band clamp, catalytic converter flanges and ring clamp.

6) The upper section of the dip stick tube can now be reinstalled and bolted back in place.

7) The final step is to install the heat-shield wrap onto the lower portion of the pipe. This is best
done by forming the shield by hand to roughly match the shape of the pipe and then sliding it into
position on the pipe. It is a tight fit with very little room to work, but a little patience will get it into
place. Once this is done, use the two provided hose clamps to secure the shield to the pipe.

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